Method and apparatus for making concentric, multiturn nested dynamoelectric machine field coils

ABSTRACT

A method and apparatus for making concentric, multiturn nested dynamoelectric machine field coils, in which first and second concentric coil form means are provided each having first and second parts for respectively forming first and second opposite end portions of the first and second coils which are respectively connected by generally straight side portions. Each of the first parts comprises two elongated, spaced, parallel pins arranged to form the first end portions of the respective coil with each of the second parts being laterally spaced from the respective first part thereby to form the side portions of the respective coil. Each of the second parts has a first section comprising two elongated, spaced, parallel pins and a second section comprising two elongated, spaced parallel pins spaced from the first section pins on the side thereof remote from the first parts and parallel with the first section pins. The pins of each of the second parts are arranged in a pattern to form the second end portions of tee respective coil with side sections respectively joined to the respective side portions and converging to and joining end sections. A flyer winder successively winds wire on the first and second coil form means respectively to form the first and second concentric coils thereon, one of the flyer and second coil form means being relatively longitudinally moved with respect to the other to a position in which the first and second coils are concentrically nested one within the other with one of the coil form means concentrically surrounding the other and with all of the pins being parallel. The first and second coil form means with the first and second nested, concentric coils thereon are moved to a position closely adjacent the elongated fingers of coil insertion apparatus with the pins extending in one direction and the coil insertion apparatus fingers is extending in the opposite direction in parallel relationship with the pins so that the coils may be removed from the pins directly onto the insertion apparatus fingers.

States [72] Inventors Robert J. Eminger;

Clayton L. Tyson, both oi Fort Wayne, Ind.

i aten [21] Appl. No. 824,121

[22] Filed May 13, 1969 [45] Patented Jan. 4, 1972 [73] Assignee Essex International Inc.

Fort Wayne, Ind.

Original application May 22, 1967, Ser. No. 640,156, now Patent No. 3,481,372, dated Dec. 2, 1969. Divided and this application May 13, 1969, Ser. No. 824,121

[54] METHOD AND APPARATUS FOR MAKING CONCENTRIC, MULTITURN NESTED DYNAMOELECTRIC MACHINE FIELD COILS 26 Claims, 40 Drawing Figs.

Primary Examiner-Charlie T. Moon Assistant Examiner--Carl E. Hall Attorney-Hood, Gust, Irish & Lundy ABSTRACT: A method and apparatus for making concentric, multiturn nested dynamoelectric machine field coils, in which first and second concentric coil form means are provided each having first and second parts for respectively forming first and second opposite end portions of the first and second coils which are respectively connected by generally straight side portions. Each of the first parts comprises two elongated, spaced, parallel pins arranged to form the first end portions of the respective coil with each of the second parts being laterally spaced from the respective first part thereby to form the side portions of the respective coil. Each of the second parts has a first section comprising two elongated, spaced, parallel pins and a second section comprising two elongated, spaced parallel pins spaced from the first section pins on the side thereof remote from the first parts and parallel with the first section pins. The pins of each of the second parts are arranged in a pattern to form the second end portions of tee respective coil with side sections respectively joined to the respective side portions and converging to and joining end sections. A flyer winder successively winds wire on the first and second coil form means respectively to form the first and second concentric coils thereon, one of the flyer and second coil form means being relatively longitudinally moved with respect to the other to a position in which the first and second coils are concentrically nested one within the other with one of the coil form means concentrically surrounding the other and with all of the pins being parallel. The first and second coil form means with the first and second nested, concentric coils thereon are moved to a position closely adjacent the elongated fingers of coil insertion apparatus with the pins extending in one direction and the coil insertion apparatus fingers is extending in the opposite direction in parallel relationship with the pins so that the coils may be removed from the pins directly onto the insertion apparatus fingers.

PATENTEDJAN 41972 3,631; 591 SHEET 010$ 27 INVENTORS ROBERT J. EMlNGER CLAYTON L. TYSON ByIH p,C-u:1,IRl$H LUNDY ATTORNEYS PATENTEDJAN M972 3.631.591

sum 020$ 27 1 INVENTORS ROBERT J. EMlNGER CLAYTON L. TYSON BYIHOOD, G us'T IRISH Lunny ATTORNEYS PATENTED JAN 4 I972 SHEET 03 0F 27 IST- INVENTORS ROBERT J. EMlNggR CLAYTON L. TY N B tHooo, G-urr, Imsn #LuuDY ATTOR NEYS PATENTEUJAN 41972 3,631,591

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INVENTO'RS ROBERT J. EMINGER CLAYTON L. TYSON B H000, Gun, Imsn Lw oY ATTORNEYS PATENTEUJAN 4:972 131631.591 sum 130E 27 EJLE 7 m-lllllmmr 8 F 8 i I i 37s E; Q 376 MM MMMMM s x i 442 3 I I a I 1 409 l I i 409 i Ill/l, 356

' sss i INVENTORS ROBERT J. EMINGER CLAYTON L. TYSON 8,012 000, 3:157, /PLI// (000 ATTORNE Y3 PATENTEDJAN 4:972 3.631591 sum IBM 27 INVENTORS ROBERT J. EMINGER CLAYTON L. TYSON ATTORNEYS PATENTED JAN 41972 sum 17 or 27 ales-31.591

INVENTORS ROBERT J. EMINGER CLAYTON L. TYSON B I-Iooo, Gusr; lam! g. 4mm,

ATTORNE YS PATENTEUJAN 41912 3631.591

SHEET 180E 27 INVE NTORS ROBERT J. EMINGER CLAYTON L. TYSON B ://aoo,6-qsr, lamltlwvo v ATTORNEYS mamwm @1972 3.631591 SHEET 18UF 27 INVENTORS ROBERT J. EMINGER CLAYTON L. TYSON 

1. The method of making concentric, multiturn, nested dynamoelectric machine field coils comprising the steps of: feeding a wire to winding means and forming a first coil thereby at an initial position on a first of two longitudinally extending, concentric coil form means; forming a second coil concentrically nested with said first coil on the second of said two coil form means, said last-named forming step including relatively longitudinally moving one of said winding means and said second coil form means with respect to the other and also moving said first coil longitudinally from said initial position to a position in which said first and second coils are concentrically nested one within the other; relatively moving both of saId coil form means with said coils thereon with respect to longitudinally extending coil transfer means from said firstnamed position to a second position with both of said coil form means closely adjacent said transfer means; and simultaneously longitudinally transferring both of said coils from said coil form means to said transfer means.
 2. The method of claim 1 wherein said longitudinal moving step comprises longitudinally moving said winding means to a position in which said second coil is formed concentrically surrounding said first coil.
 3. The method of claim 1 wherein one of said coil form means concentrically surrounds the other in said first-named position.
 4. The method of claim 1 wherein each of said coil form means has a distal end, one of said last-named forming and moving steps including relatively longitudinally moving both of said coil form means with said coils thereon with respect to said winding means to a position in which said distal ends are longitudinally spaced from said winding means.
 5. The method of claim 1 wherein said wire is paid out from a source thereof during the forming of said first and second coils, and comprising the further step of pulling out from said source a predetermined length of slack in said wire following the forming of said first coil and prior to forming said second wire.
 6. The method of making concentric, multiturn, nested dynamoelectric machine field coils comPrising the steps of: feeding a wire to winding means and forming a first coil thereby on a first of two longitudinally extending, concentric coil form means; forming a second coil concentrically nested with said first coil on the second of said two coil form means, said last-named forming step including relatively longitudinally moving one of said winding means and said second coil form means with respect to the other to a position in which said first and second coils are concentrically nested one within the other; relatively moving both of said coil form means with said coils thereon with respect to longitudinally extending coil transfer means from said first-named position to a second position with both of said coil form means closely adjacent said transfer means; and simultaneously longitudinally transferring both of said coils from said coil form means to said transfer means wherein said last-named moving step includes relatively moving said first and second coil form means with said coils therein with respect to said winding means from said first-named position to an intermediate position, and comprising the further steps of relatively moving third and fourth coil form means with respect to said winding means to the initial positions of said first and second coil form means, similarly forming third and fourth concentric nested coils on said third and fourth coil form means, relatively moving said first and second coil form means with said first and second coils thereon from said intermediate position to said second position and simultaneously relatively moving said third and fourth coil form means with said third and fourth coils thereon from said first-named position thereof to said second position, and transferring said third and fourth coils to said transfer means simultaneously with said transfer of said first and second coils thereto.
 7. The method of claim 6 wherein said steps of relatively moving said first and second coil form means to said intermediate position and of relatively moving said third and fourth coil form means to said initial position comprises rotating all of said coil form means a partial turn.
 8. The method of claim 6 wherein said first and second coils are wound in a first direction and said third and fourth coils are wound in the opposite direction.
 9. The method of claim 6 wherein said wire is paid out from a source thereof and comprising the further steps of securing the free end of said wire prior to forming said first coil, releasing said free end of said wire upon completion of the forming of said second coil, pulling out a length of wire from said source, severing said wire intermediate said length thereby leaving an end extending from said second coil and a new free end extending from said source, and securing said new free end prior to forming said third coil.
 10. The method of claim 1 wherein each of said first and second coil form means includes first and second parts which respectively form opposite end portions of the respective coil, said last-named moving step including removing the second parts of both of said first and second coil form means from the respective coils thereby freeing the respective end portions, and relatively moving said first parts of both of said first and second coil form means with said first and second coils thereon from said first-named position to said second position.
 11. The method of claim 10 wherein said last-named moving step includes relatively moving said first parts of both of said first and second wire form means from said first-named position to an intermediate position, and comprising the further steps of relatively moving third and fourth coil form means, substantially identical respectively to said first parts of said first and second coil form means, with respect to said winding means to the initial position of said first parts of said first and second coil form means, returning said second parts of said first and second coil form means, returning said second parts of said first and seconD coil form means to their initial positions, similarly forming third and fourth concentric nested coils on said second parts of said first and second coil form means and said third and fourth coil form means, removing said second parts of said first and second wire form means from said third and fourth coils thereby freeing the respective end portions, relatively moving said first parts of said first and second wire form means from said intermediate position to said second position and simultaneously relatively moving said third and fourth coil form means with said third and fourth coils thereon from said first-named position thereof to said second position, and transferring said third and fourth coils to said transfer means simultaneously with said transfer of said first and second coils thereto.
 12. Apparatus for forming concentric, multiturn, nested dynamoelectric machine field coils comprising: first and second longitudinally extending, concentric coil form means; means for successively winding a wire on said first and second coil form means in a winding position thereby respectively to form first and second concentric coils thereon, said first coil being wound at an initial position; means for concentrically nesting said coils one within the other including means for relatively longitudinally moving one of said winding means and said second coil form means with respect to the other and means for longitudinally moving said first coil from said initial position to a position in which said first and second coils are concentrically nested one within the other, one of said coil form means concentrically surrounding the other in said nested position of said coils; longitudinally extending means for transferring coils; and means for relatively moving both of said coil form means with said coils thereon with respect to said transfer means from said nested position to a second position with both of said coil form means closely adjacent said transfer means whereby said coils may be removed from said coil form means directly to said transfer means.
 13. The apparatus of claim 12 wherein said first-named moving means said winding means to said nested position in which said second coil is wound concentrically surrounding said first coil.
 14. The apparatus of claim 12 wherein each of said coil form means has a distal end, said first-named moving means including means for relatively longitudinally moving both of said coil form means with said coils thereon with respect to said winding means to a position with said distal ends of said coil means longitudinally spaced from said winding means.
 15. Apparatus for forming concentric, multiturn, nested dynamoelectric machine field coils comprising: first and second longitudinally extending, concentric coil form means; means for successively winding a wire on said first and second coil form means in a winding position thereby respectively to form first and second concentric coils thereon, means for relatively longitudinally moving one of said winding means and second coil form means with respect to the other to a position in which said first and second coils are concentrically nested one within the other, one of said coil form means concentrically surrounding the other in said nested position of said coils; longitudinally extending means for transferring coils; and means for relatively moving both of said coil form means with said coils thereon with respect to said transfer means from said nested position to a second position with both of said coil form means closely adjacent said transfer means whereby said coils may be removed from said coil form means directly to said transfer means wherein each of said first and second coil form means comprises first and second parts for respectively forming first and second opposite end portions of said first and second coils which are respectively connected by generally straight side portions; each of said first parts comprising at least two elongated, spaced, parallel pins arranged in a pattern to form said first end portions of the respective coil, each of said second parts being laterally spaced from the respective first part thereby to form said side portions of the respective coil; each of said second parts having a first section comprising at least two elongated, spaced, parallel pins and a second section comprising at least one elongated pin spaced from the first section pins on the side thereof remote from the respective first part and parallel with the first section pins, all of said pins being parallel in said winding and nested positions, the pins of each of said second parts being arranged in a pattern to form said second end portion of the respective coil with side sections respectively joined to the respective side position and converging to and joining an end section, said last-named means moving at least said second parts of said first and second coil form means with said first and second coils respectively thereon to said second position.
 16. The apparatus of claim 15 wherein said winding means is rotatable about a first axis, all of said pins in said winding and nested position being parallel with said first axis, said first and second parts of said first and second coil form means in said winding and nested position being respectively spaced on opposite sides of said first axis and lying on a second axis which intersects said first axis and is normal thereto, the two pins of each of said first parts being spaced on opposite sides of said second axis and lying on an axis normal to said second axis, the two pins of each of said first section being spaced on opposite sides of said second axis and lying on an axis normal to said second axis, each of said second sections comprising two pins spaced on opposite sides of said second axis and lying on an axis normal to said second axis, the axis of the two pins of each of said second sections being spaced from the axis of the two pins of the respective first section on the side thereof remote from said first axis.
 17. The apparatus of claim 15 wherein each of said second sections comprises two pins, the pins of both of said first sections lying on a first circle with the pins of one coil form means respectively spaced radially outwardly from the pins of the other coil form means, the pins of both of said second sections lying on a second circle concentric with and smaller than said first circle with the pins of said one coil form means being respectively spaced radially outwardly from the pins of said other coil form means, said first and second section pins of each of said second parts being arranged so that said side sections of said second end portions respectively lie on radii of said circles with the respective end sections forming chords of said second circle, the two pins of each of said first parts respectively forming generally straight first end portions which are parallel with the respective end sections of the second end portions.
 18. The apparatus of claim 17 wherein said transfer means includes a plurality of elongated spaced, parallel finger elements lying on a third circle, said first and second section pins and said finger elements being parallel and the axis of said circles being aligned in said second position.
 19. The apparatus of claim 18 wherein said pins of said second coil form means parts have distal ends extending in one direction in said second position, said finger elements having distal ends extending in the direction opposite said one direction in said second pattern, said third circle being smaller than said first circle and larger than said second circle, the distal ends of said third circle of finger elements extending axially in intermeshing relationship between the distal ends of said first and second circles of first and second section pins in said second position with the spaces between said finger elements being radially aligned with respective ones of said side sections whereby said coils may be transferred axially from said pins onto said finger elements.
 20. THe apparatus of claim 17 wherein each pair of first and second section pins which mutually form a side section of a second end portion lie on a radius of said circles, said first section pins having a larger diameter than said second section pins so that the respective side sections lie on radii of said circles.
 21. The apparatus of claim 17 wherein said first and second coil form means respectively form first and second concentric, nested coils of a first pole group, and further comprising third and fourth coil form means for respectively forming third and fourth concentric, nested coils of a second pole group, said third and fourth coil form means including at least first and second section pins identical to said first and second section pins of said first and second coil form means, said first and second section pins of said third and fourth coil form means respectively lying on said first and second circles, and means for moving said first and second section pins of said first and second coil form means with said first and second coils thereon from said nested position to an intermediate position and for simultaneously moving said first and second section pins of said third and fourth coil form means to said winding position.
 22. The apparatus of claim 12 wherein each of said first and second coil form means comprises first and second spaced parts for respectively forming first and second opposite end portions of said first and second coils which are respectively connected by generally straight side portions, said last-named moving means including means for removing said first parts of both of said coil form means from said first and second coils thereby freeing said first end portions, and means for moving said second parts with said first and second coils thereon to said second position.
 23. The apparatus of claim 12 wherein each of said first and second coil form means comprises first and second spaced parts for respectively forming first and second opposite end portions of said first and second coils which are respectively connected by generally straight side portions, and further comprising third and fourth coil form means including third parts substantially identical to said second parts of said first and second coil form means parts, and means for interchanging the positions of said second and third parts whereby third and fourth concentric, nested coils may be formed on said first and third parts.
 24. The apparatus of claim 23 further comprising means for guiding said wire from a source thereof to said winding means, said wire initially having a free end on the side of said winding means remote from said source means for selectively receiving said free end during forming of said first and second coils and means for pulling out a length of wire from said source following forming of said first and second coils, said securing means including means for severing said length of wire and for securing the new free end thereof during forming of said third and fourth coils.
 25. The apparatus of claim 12 further comprising means for guiding said wire from a source thereof to said winding means, and means for pulling out a predetermined length of said wire from said source following winding of said first coil thereby to form a connection between said first and second coils.
 26. The apparatus of claim 23 further comprising means for selectively rotating said winding means in opposite directions, said last-named means rotating said winding means in one direction during forming of said first and second coils and in the opposite direction during forming of said third and fourth coils. 